Methods for producing security and tracking systems including energy harvesting components for providing autonomous electrical power

ABSTRACT

A method is provided that integrates a unique set of structural features for concealing self-powered sensor and communication devices in aesthetically neutral, or camouflaged, packages that include energy harvesting systems that provide autonomous electrical power to sensors, data processing and wireless communication components in the portable, self-contained packages. Color-matched, image-matched and/or texture-matched optical layers are formed over energy harvesting components, including photovoltaic energy collecting components. Optical layers are tuned to scatter selectable wavelengths of electromagnetic energy back in an incident direction while allowing remaining wavelengths of electromagnetic energy to pass through the layers to the energy collecting components below. The layers uniquely implement optical light scattering techniques to make the layers appear opaque when observed from a light incident side, while allowing at least 50%, and as much as 80+%, of the energy impinging on the energy or incident side to pass through the layer.

BACKGROUND

This application is related to U.S. patent application Ser. No.15/416,491, filed in the United States Patent and Trademark Office(USPTO) on Jan. 16, 2017, entitled “Security And Tracking SystemsIncluding Energy Harvesting Components For Providing AutonomousElectrical Power,” which issued as U.S. Pat. No. 9,923,514 on Mar. 20,2018, the disclosure of which is hereby incorporated by reference hereinin its entirety.

1. Field of the Disclosed Embodiments

This disclosure is directed to a method for forming a unique set ofstructural features for concealing self-powered sensor and communicationdevices in aesthetically neutral, or camouflaged, packages that includeenergy harvesting systems that provide autonomous electrical power tosensors, and data processing and wireless communication components inthe portable, self-contained packages. Color-matched, image-matchedand/or texture-matched optical layers, which provide an essentially sameappearance from any viewing angle, and provide superior lighttransmission across the range of light impingement angles, are formedover energy harvesting components, including photovoltaic components,and sensor components, in the packages, the energy harvesting componentsself-powering the packages.

2. Related Art

The disclosure of U.S. patent application Ser. No. 15/006,143 (the 143application), entitled “Systems and Methods for Producing Laminates,Layers and Coatings Including Elements for Scattering and PassingSelective Wavelengths of Electromagnetic Energy,” which was filed in theUSPTO on Jan. 26, 2016 and which published as U.S. Patent PublicationNo. US 2016-0306078 A1 on Oct. 20, 2016; and the disclosure of U.S.patent application Ser. No. 15/006,145 (the 145 application), entitled“Systems and Methods for Producing Objects Incorporating SelectiveElectromagnetic Energy Scattering Layers, Laminates and Coatings,” whichwas filed in the USPTO on Jan. 26, 2016, and which issued as U.S. Pat.No. 10,795,062 on Oct. 6, 2020, each of which are hereby incorporated byreference herein in their entirety, describe structures for formingselectably energy transmissive layers and certain real world use casesin which those layers may be particularly advantageously employed.

The 143 and 145 applications note that, in recent years, the fields ofenergy harvesting and ambient energy collection have gainedsignificantly increased interest. Photovoltaic (PV) cell layers andother photocell layers, including thin film PV-type (TFPV) materiallayers, are advantageously employed on outer surfaces of particularstructures to convert ambient light to electricity.

Significant drawbacks to wider proliferation of photocells used in anumber of potentially beneficial operating or employment scenarios arethat the installations, in many instances, unacceptably adversely affectthe aesthetics of the structures, objects or host substrate surfaces onwhich the PV layers are mounted for use. PV layers typically must begenerally visible, and the visual appearance of the PV layers themselvescannot be significantly altered from the comparatively dark greyscale toblack presentations provided by the facial surfaces without renderingthe layers significantly less efficient, substantially degrading theiroperation. Presence of photocells and PV layers in most installationsis, therefore, easily visually distinguishable, often in an unacceptablydistracting, or appearance degrading, manner. Based on these drawbacksand/or limitations, inclusion of photocell arrays, and evensophisticated TFPV material layers, is often avoided in manyinstallations, or in association with many structures, objects orproducts that may otherwise benefit from the electrical energyharvesting capacity provided by these layers. PV layer installations areoften shunned as unacceptable visual detractors or distractors adverselyaffecting the appearance or ornamental design of the structures, objectsor products.

The last several decades have seen an expansive proliferation in allmanner of self-powered (read “battery-powered”) devices. Developmentalefforts are particularly evident in the introduction and use of remotebattery-powered sensors and sensor arrays in commercial, industrial,military and security settings for such functions as personnel and/orasset tracking, intrusion detection and all manner of surveillancetasking.

In many commercial, asset tracking, security and operation employmentscenarios, the use of batteries has its limitations. “Right sizing” thebatteries for a particular surveillance and tracking package result inoperationally trading off certain surveillance, sensor, tracking and/orcommunication capabilities for field-deployable packages in an effort tolimit the power drain on the batteries sized for a particular use.

Another drawback, particularly in covert surveillance scenarios, is thateven the best batteries will, at some point, need to be changed. Thereare operating circumstances in which changing batteries is eitherunacceptable, or impossible. Surveillance and tracking sensors go blindwhen the batteries deplete, and the packages in which the sensors arehoused are, thereby, rendered useless.

Battery technologies continue to improve and efficiencies in sensors andcommunication components mitigates the power drain in the batteries.Nevertheless, there remain finite limits to battery capacity. Also, thetypical chemical residue as a battery depletes may be detectable withappropriate detection resources. Combining these disadvantages with thedrawbacks in applying conventional environmental energy harvesting forre-charging the batteries given the identified shortfalls in the use ofconventional photovoltaic elements for the reasons enumerated above,leads to a conclusion that, while all of the component elements appearto exist, there is no currently-available solution to economicallyaddress the combination of apparent shortfalls across a broad spectrumof employment scenarios.

There are ongoing efforts to reduce power needs of sensors, processorsand other electronics components that attempt to address powerconsumption issues. Generally, however, these efforts remain“battery-centric,” with an objective of reducing battery depletionrates, but not with eliminating batteries altogether. Efforts at batteryelimination, even as new low-energy communications protocols/standardsare being developed specifically for “batteryless” wireless nodes, arestalled based on a lack of an ability to hide batteryless wirelessnodes. The efforts are hamstrung with the inability to be divorced fromconventional photovoltaic elements. Put another way, there is noaesthetically neutral, or aesthetically pleasing manner by which topresent the nodes, particularly in residential, and retail, office, andother commercial environments.

In this regard, the formidable challenges associated with the massivelogistics effort involved in changing/maintaining batteries in largewireless sensor/security/safety networks remain. These challengesadversely impact all manner of technologic innovation. For example,consider that industry estimates suggest that, based on the number ofpowered nodes that are anticipated to populate the Internet of Things(IoT), as envisioned, in the comparatively near future, and even if abattery lasts for ten years, something well in excess of 250 millionbatteries per day will need to be changed in order to keep the networkrunning. Those estimates are conservative and they drive not only theefforts to reduce the overall load on batteries as a whole but alsoefforts to find battery replacements. The lack of an effective powersourcing scheme to support the broad expansion that the IoT may enjoy iscited as a major factor slowing the adoption and proliferation of theIoT.

SUMMARY

The 143 and 145 applications introduce systems and methods that provideparticularly formulated energy or light transmissive overlayers, whichmay be provided to “hide” typical photoelectric energy generatingdevices, and sensor components. These overlayers, generally in the formof surface treatments and/or coverings, are formulated to support uniqueenergy transmission and light refraction schemes to effectively “trick”the human eye into seeing a generally opaque surface when observed froma light incident side. These overlayers are formulated to supporttransmission of visual light, or near-visual light, in a manner thatallows a substantial percentage (at least 50% and up to 80+%) of theelectromagnetic energy impinging on the surface of the overlayer topenetrate the surface treatments and coverings in a comparativelyunfiltered manner. The overlayers also provide an opaque appearingsurface that exhibits an essentially same appearance when viewed fromany viewing angle, and that support a consistently superior lighttransmission across a full range of light impingement angles. The energytransmissive layers disclosed in the 143 and 145 applications rely on aparticular cooperation between refractive indices of the disclosedmicron-sized particles or spheres with cooperating refractive indices ofthe matrix materials in which those micron-sized particles are suspendedfor deposition on prepared surfaces. This coincident requirement betweenthe refractive indices of the matrix material on the refractive indicesof the suspended particles limits deposition of these materialsuspensions of particles on substrates to techniques in which thedeposition of the materials can be carefully controlled.

U.S. patent application Ser. No. 15/415,851, entitled “Compositions OfMaterials For Forming Coatings And Layered Structures Including ElementsFor Scattering And Passing Selectively Tunable Wavelengths OfElectromagnetic Energy,” and Ser. No. 15/415,857, entitled “Methods ForMaking Compositions Of Materials For Forming Coatings And LayeredStructures Including Elements For Scattering And Passing SelectivelyTunable Wavelengths Of Electromagnetic Energy,” and Ser. No. 15/415,864,entitled “Delivery Systems and Methods For Compositions Of Materials ForForming Coatings And Layered Structures Including Elements ForScattering And Passing Selectively Tunable Wavelengths OfElectromagnetic Energy,” each of which was filed Jan. 25, 2017, and thedisclosures of which are hereby incorporated by reference herein intheir entirety, improve upon the inventive concepts disclosed in the 143and 145 applications by controlling the refractive indices of theparticles themselves to capture all of the physical parameters leadingto independent color selection in the particles, thereby easing relianceon a cooperative synergy between a composition of the particles and acomposition of the binder or matrix material in which the particles aresuspended.

It would be advantageous to apply the selectively colorable and/ortexturizable overlayers disclosed in detail in the above applications toenergy harvesting elements, sensors, communication components andassociated circuitry to field self-powered sensor and communicationpackages that (1) provide detection capabilities to detect any sensormeasurable parameters according to the capabilities of installedsensors; (2) camouflage or otherwise commercially package the sensors,communication and energy harvesting elements as a particular commercialor other operating scenario dictates; (3) provide communicationconnectivity by establishing wireless communication with compatiblereceiving nodes and/or by establishing an ad hoc mesh network betweencooperating packages; and/or (4) eliminate a requirement to changebatteries thereby avoiding disadvantages associated with batterydepletion including loss of sensor and/or communication capability, orexposure of, for example, covert package deployment necessitated bybattery replacement.

Exemplary embodiments may provide substantially transparent particles,including micron-sized particles, in a cooperating binder matrix toproduce material compositions for layers in which refractive indices ofthe constituent elements of the layers are cooperatively controlled toproduce repeatable coloration in the layers causing them to appearopaque from a light-incident side, and yet retaining a capacity totransmit at least 50%, and as much as 80+%, of the incidentelectromagnetic energy therethrough to impinge, for example, onphotoelectric or photovoltaic energy harvesters positioned behind thelayers.

Exemplary embodiments may form energy transmissive layers overphotovoltaic arrays, the energy transmissive layers providing an opaqueappearing surface that exhibits an essentially same appearance whenviewed from any viewing angle, and supporting a consistently superiorlight transmission across a full range of light impingement angles.

Exemplary embodiments may provide a TFPV material layer on a substrate.In embodiments, sensor and communication elements may also be providedon the substrate. The disclosed TFPV material layers, and the otherelemental components, may be adhesively conformed to the substrate andthen hidden by being overcoated with the disclosed energy transmissiveoverlayer material. The other elemental components may include, but notbe limited to, signal conditioning and other electronics componentsbetween the sensors themselves and the communications elements.

Exemplary embodiments may provide electrical circuits that convert theenergy collected by the TFPV layer into usable electrical power for useby the sensors, communication components and other electrically-poweredelements in self-powered packages.

These and other features, and advantages, of the disclosed systems andmethods are described in, or apparent from, the following detaileddescription of various exemplary embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

Various exemplary embodiments of the disclosed methods that provideschemes for forming a unique set of structural features for concealingself-powered sensor and communication devices in aesthetically neutral,or camouflaged, packages that include energy harvesting systems thatprovide autonomous electrical power to sensors, data processing andwireless communication components in the portable, self-containedpackages, will be described, in detail, with reference to the followingdrawings, in which:

FIG. 1 illustrates a schematic diagram of an exemplary objectenergy/light scattering surface layer disposed on a structural bodymember substrate according to this disclosure;

FIG. 2 illustrates a schematic diagram of an exemplary self-poweredsensor and communication device for local or remote deployment insurveillance and monitoring scenarios including an energy harvester,light sensitive (or other physical parameter measuring) sensor elementsand communication capabilities mounted in a structural body memberhaving a surface constituted of an energy/light scattering surface layeraccording to this disclosure;

FIGS. 3A-3D illustrate a series of schematic diagrams of steps in anexemplary process for forming a laminated energy harvesting, sensor andcommunication component, with at least one layer constituted as anenergy/light scattering layer, according to this disclosure;

FIG. 4 illustrates an exemplary embodiment of a detail of anenergy/light scattering layer usable in the energy harvesting systemsaccording to this disclosure;

FIG. 5 illustrates a schematic diagram of an exemplary communicationnetwork within which a self-powered sensor and communication deviceaccording to this disclosure may operate;

FIG. 6 illustrates a schematic diagram of an exemplary assembly lineusable for automated forming of the exemplary laminated energyharvesting, sensor, communication and other components on a substrate toform a self-powered sensor and communication device according to thisdisclosure; and

FIG. 7 illustrates a flowchart of an exemplary method for integrating aunique energy harvesting system, including an energy/light scatteringlayer, sensor, communication and other components on a substrate to forma self-powered sensor and communication device according to thisdisclosure.

DETAILED DESCRIPTION OF EMBODIMENTS

The disclosed methods for forming unique set of structural features forconcealing self-powered sensor and communication devices inaesthetically neutral, or camouflaged, packages that include energyharvesting systems that provide autonomous electrical power to sensors,data processing and wireless communication components in portable,self-contained packages, will be described as being particularly usablefor personnel and/or asset (package) tracking, intrusion detection andall manner of surveillance tasking, including wide area and covertsurveillance, and for carrying into effect certain monitoring functions.These real-world applications for the disclosed energy harvesting,sensor and communication systems should not be considered as limitingthose systems. Rather, the disclosed embodiments are intended to providean overview of a particular system architecture that may be implementedto autonomously provide electrical power to integral sensor and/orcommunications capabilities in support of any one of a number of devicesthat may be used for (1) surveillance tasks (including wide-areasurveillance and intrusion detection among others) and (2) individualpersonnel or asset tracking (including tagging cargo, commercialpackages, personal luggage and individuals with active identifiers andgeo-locating capabilities).

It should be appreciated that surveillance, tracking and monitoringfunctions that may be facilitated with self-powered sensor andcommunication devices as described herein are not limited to those thatmay be considered to fall in the traditional category of “security”monitoring. Rather, employment of the disclosed self-powered sensor andcommunication devices may be equally effective in surveillance, trackingand monitoring functions that may be associated with traditional“safety” concerns.

Consider, for example, a function of employing sensors to monitortemperatures of wheel bearings on rail cars (over-heated wheel bearingshaving been cited as a comparatively high percentage cause of trainderailings). There are currently proposed regulations directed atcountering this risk by providing that wheel bearings on rail cars mustbe monitored in real-time. Delays in implementation of such importantsafety regulations are understood to center around the cost-prohibitivenature of implementing an effective monitoring scheme. Adapting thedisclosed self-powered sensor and communication devices with appropriatethermal sensors, in an undetectable deployable self-contained package,may effectively address this known gap in safe and efficient operationsof railcars. Operational data, as will be described in greater detailbelow, may be sensed, stored and/or transmitted to carry into effect thereal-time monitoring function in this real-world scenario.

Interestingly, an area in which security and safety concerns overlap isin the monitoring of all manner of packages from hand-carried packagesto containerized shipping for the presence of hazardous materials.Appropriately-sized self-powered sensor and communication devicesaccording to this disclosure may address this real-world employmentscenario as well.

Reference will be made to substantially transparent multi-layermicron-sized particles, and the material compositions in which thoseparticles may be delivered, and the systems and methods for delivery ofthose material compositions onto substrate surfaces that have beenpreviously provided with conformal photovoltaic arrays, particularly ina form of a TFPV material layer, according to this disclosure. Thedisclosed schemes may include techniques for depositing and curingmaterial compositions that suspend substantially transparent multi-layermicron-sized particles in substantially transparent binder or matrixmaterials, techniques for developing material compositions intostructural layers, and delivery systems and techniques for developingthe multi-layered structure, which may be a laminated structure, inwhich color-selectable electromagnetic energy transmissive layers areformed over the photovoltaic components, as well as the sensor andcommunication elements. These layers, once formed, may selectivelyscatter specific wavelengths of electromagnetic energy impinging on anenergy incident side of the layers, while allowing remaining wavelengthsof the electromagnetic energy to pass therethrough. These layers mayuniquely implement optical light scattering techniques in such energytransmissive layers to provide an aesthetically neutral, or a surfacepresentation selectable, outer surface that is substantially comparablein appearance to any painted surface. These layers may also provide anopaque appearing surface that exhibits an essentially same appearancewhen viewed from any viewing angle, and that supports a consistentlysuperior light transmission across a full range of light impingementangles. Because the disclosed “coatings” do not include pigmentmaterials, the overlayers comprised of these substantially transparentmaterials are not susceptible to fading over time. In order to provide ausable electrical energy, the disclosed overlayers may be particularlyformed to selectively scatter particular wavelengths of electromagneticenergy, including light energy in the visual, near-visual or non-visualrange, while allowing remaining wavelengths to pass therethrough with atransmissive efficiency of at least 50%, and as much as 80+%, withrespect to the impinging energy.

Additional details regarding the above-discussed energy transmissivelayers are available in the various related applications cataloguedabove, the disclosures of which are incorporated by reference herein intheir entireties.

Exemplary embodiments described and depicted in this disclosure shouldnot be interpreted as being specifically limited to any particularlylimiting material composition of the individually-describedsubstantially transparent multi-layer micron-sized particles, and thebinder matrices in which those particles may be suspended, except asindicated according to the material properties generally outlined below.Further, the exemplary embodiments described and depicted in thisdisclosure should not be interpreted as specifically limiting theconfiguration of any of the described layers, or of the substrates onwhich the disclosed energy harvesting structures may be formed.

References will be made to individual ones, or classes, of energy/lightcollecting sensor components and energy/light activated devices that maybe operationally mounted in, installed in or placed behind the disclosedenergy/light scattering, light directing or light transmissive layers soas to be hidden from view when an object including such sensor componentor device is viewed from a viewing, observation or light incident outersurface of the object or layer, from which perspective the energy/lightscattering, light directing or light transmissive layers may appear“opaque” to the incident electromagnetic energy. These references areintended to be illustrative only and are not intended to limit thedisclosed concepts, compositions, processes, techniques, methods,systems and devices in any manner. It should be recognized that anyadvantageous use of the disclosed structures and schemes for providingan autonomous energy harvesting capability in self-powered packagesemploying systems, methods, techniques, and processes such as thosediscussed in detail in this disclosure is contemplated as being includedwithin the scope of the disclosed exemplary embodiments.

In this regard, the disclosed systems and methods will be described asbeing particularly adaptable to hiding certain photovoltaic materials,and the emerging class of increasingly efficient TFPV materials ormaterial layers, which are typically mils thick, on the surfaces of, orwithin objects, behind layers that may appear opaque from a viewing,observation or light incident side. As used throughout the balance ofthis disclosure, references to TFPV material layers are not intended toexclude other types of photovoltaic materials, and/or any generallyknown configuration as to any photocells.

FIG. 1 illustrates a schematic diagram 100 of an exemplary objectenergy/light scattering surface layer 120 disposed on a transparentportion of a body structure 110. As shown in FIG. 1, the energy/lightscattering layer 120 is configured to allow first determined wavelengthsof energy/light, WLp, to pass through the energy/light scattering layer120. The configuration of the energy/light scattering layer 120simultaneously causes certain second determined wavelengths ofenergy/light, WLs, to be scattered back in an incident directionsubstantially as shown.

The energy/light scattering layer 120 may be configured of substantiallytransparent micron-sized particles of varying sizes. In embodiment,these particles may be substantially in a range of 5 microns or less.The substantially transparent micron-sized particles may be stabilizedin structural or other layers further comprised ofsubstantially-transparent matrix materials including, but not limitedto, dielectric materials. An ability to configure the substantiallytransparent micron-sized particles to “tune” the light scatteringsurface of the light scattering layer 120 to scatter particular seconddetermined wavelengths of energy/light, WLs, may provide the capacity ofthe energy/light scattering layer 120 to produce a desired visualappearance in a single color, multiple colors, or according to animage-wise visual presentation provided by the energy/light scatteringlayer 120. Put another way, depending on a particular composition of thesubstantially transparent micron-sized particles comprising theenergy/light scattering layer 120 (or multiple layers), one or morecolors, textures, color patterns, or color-patterned images may bevisually produced by the energy/light scattering layer 120.

In cases where the incident energy includes wavelengths in the visualspectrum, refractive indices of the energy/light scattering layer 120may be selectively tuned based on structural compositions of thesubstantially transparent micron-sized particles, and thesubstantially-transparent binder or matrix materials in which theparticles are suspended. In embodiments, the energy/light scatteringlayer 120 is intended to appear as a single color across a surface ofthe energy/light scattering layer 120. To this end, the composition ofthe particles and matrix scheme across the surface of the energy/lightscattering layer 120 may be substantially identical, or homogenous.

A light scattering effect of the energy/light scattering layer 120 maybe produced in response to illumination generally from ambient light ina vicinity of, and/or impinging on, the surface of the energy/lightscattering layer 120. Alternatively, the light scattering effect of theenergy/light scattering layer 120 may be produced in response to directillumination generally produced by some directed light source 130focusing illumination on the light-incident surface of the energy/lightscattering layer 110.

FIG. 2 illustrates a schematic diagram of an exemplary self-poweredsensor device 200 for remote deployment in surveillance, tracking andmonitoring scenarios. The self-powered sensor device 200 may include anenergy harvesting element 240, a sensor element 250 and communicationcapabilities mounted in or on a structural body member 210. The energyharvesting element 240 may provide electrical power to the sensorelement 250. The sensor element 250 may be configured to measure atleast one physical parameter and to output a signal based on themeasured physical parameter. The physical parameters measured by thesensor element may include, but not be limited to, light, heat andmotion. The self-powered sensor device 200 may include a processor 270that may control operations of the various elements in the self-poweredsensor device and/or convert output signals from the sensor element 250to data communications for transmission by the wireless communicatingdevice 280. The self-powered sensor device 200 may also include a datastorage device 275 for storing data from the sensor element 250, datatransmissions generated by the processor 270, and/or operatinginstructions for the various elements in the self-powered sensor device200.

The self-powered sensor device 200 may have a surface constituted of anenergy/light scattering surface layer 220 according to this disclosure.As shown in FIG. 2, at least first determined wavelengths, WLp, of theambient light in a vicinity of the light scattering layer 220, or oflight directed from a light source 230 at the light scattering layer220, may pass through the light scattering layer 220, in the mannerdescribed above with reference to the embodiment shown in FIG. 1, whileat least second determined wavelengths, WLs, of the ambient light, orthe directed light, may be scattered back in the incident direction inthe manner described above. The at least first wavelengths, WLp, of theambient light, or the directed light, may be caused to impinge on afacing or facial surface of the energy harvesting element 240, which maybe in a form of a photocell or a TFPV material covered component. The atleast first wavelengths of energy/light, WLp, impinging on an energyharvesting element 240 may cause the energy harvesting element 240 togenerate electrical energy which may be stored in a compatible energystorage device 260 allowing the combination of the energy harvestingelement 240 and the compatible energy storage device 260 to power othercomponents in the self-powered sensor device 200.

The at least first wavelengths, WLp, of the ambient light, or thedirected light, may be caused to impinge on a facing or facial surface(or a lens) of sensor element 250. At least the first wavelengths, WLp,of the ambient light, or the directed light, may cause the sensorelement 250 to generate a particular output signal, which may be outputdirectly, or via some manner of sensor interface 265, to the processor270 for signal processing, as indicated above. In embodiments, aconfiguration of the sensor element 250 may enable emission ofelectromagnetic energy in a form broadly of a sensor signal outward froma sensor side of the light scattering layer 220 through the lightscattering layer 220 to, for example, be reflected off a target formeasurement of a parameter of the target.

The first wavelengths of energy/light, WLp, impinging on the sensorelement 250 may be conditioned through one or more energy/lightfocusing/filtering layers that may be in a form of optical isolators,prisms, lenses or the like, and that may focus, filter or otherwisecondition the first wavelengths of energy/light, WLp, as may beappropriate to modify an input of the energy to the sensor element 250to be compatible with the capabilities, or input requirements, of thesensor element 250, particularly when provided in the form of a cameraand/or other imaging device. Those of skill in the art will recognizethat the first wavelengths of energy/light, WLp, may require minormodification and/or re-filtering to be rendered compatible.

In embodiments, the first wavelengths of energy/light, WLp, may also orotherwise be partially blocked from further transmission to and throughthe structural body member 210 by one or more opaque, near opaque, ordarkened energy/light shades, which may be in a form of solid objectbody components. The energy/light shades may substantially shield orshadow portions of the structural body member 210, and any area orsensor placed behind the energy/light scattering layer 220 in thestructural body member 210 from exposure to the first wavelengths ofenergy/light, WLp. Energy/light filtering layers (or elements) andenergy/light shades may be arranged in any configuration to functionexclusively, or otherwise to function cooperatively, to control and/orotherwise direct the transmission of the first wavelengths ofenergy/light, WLp, through the structural body member 210 to one or bothof the energy harvesting element 240 and the sensor element 250.

As noted briefly above, the data storage device 275 may be provided tostore operating programs to be referenced by the processor 270 incarrying out functional control of the self-powered sensor device 200.Separately, the data storage device 275 may be provided to at leasttemporarily store information obtained via the sensor element 250, andas may be modified by the sensor interface 265.

A wireless communication capability may be provided with the inclusionof the wireless communicating device 280, which may be in a form of alow-power radio or satellite communication transmitter operatingaccording to any one or more of a number of wireless communicatingprotocols, including such protocols as may be usable to cause theself-powered sensor device to communicate with other similarly-situatedself-powered sensor devices to form an ad hoc wireless communicationmesh network between such similarly-situated devices. See FIG. 5. Asindicated, the wireless communicating devices 280 may operate accordingto any compatible wireless signal processing protocol including, but notlimited to, Wi-Fi, WiGig, Bluetooth®, Bluetooth® Low Energy (LE) (alsoreferred to as Bluetooth® Smart or Version 4.0+ of the Bluetooth®specification), ZigBee®, or other similar wireless signal processingprotocol for communication of wireless signals to appropriate local orremote compatible receivers.

The self-powered sensor device 200 may include ageolocation/triangulation device 285. The geolocation/triangulationdevice 285 may be a function of the processor 270 in communication withthe wireless communicating device 280, or may constitute a stand-aloneelement in the exemplary self-powered sensor device 200. Thegeolocation/triangulation device 285 may provide a capacity for theself-powered sensor device 200 to determine its own location, or itslocation with regard to other self-powered sensor devices with which itmay be in communication. In embodiments, the geolocation/triangulationdevice 285 may constitute, for example, a global positioning satellite(GPS) receiver. In other embodiments, the geolocation/triangulationdevice 285 may operate in concert with the wireless communicating device280 to triangulate a position of the self-powered sensor device 200 withrespect to known positions of data gateway access nodes and, forexample, an assessment of received signal strengths (RSS) from thosenodes. Virtually any capability by which a radio receiver may be able toassess an own position of the radio receiver may be implemented in theself-powered sensor device 200.

FIGS. 3A-3D illustrate a series of schematic diagrams of steps in anexemplary process 300 for forming a laminated energy harvesting, sensorand communication component, with at least one layer constituted as alight scattering constituent layer, according to this disclosure.

As shown in FIG. 3A, a substrate component 310 may be provided.

As shown in FIG. 3B, a photovoltaic layer (or component) 315 may bedisposed on the substrate component 310. The photovoltaic layer 315 maycomprise one or more of a photocell, an array of photocells, or a TFPVmaterial layer. Separately, one or more of a sensor device 317 and acommunicating device 319 may also be disposed on the substrate component310. Further, the photovoltaic layer 315, the sensor device 317 and acommunicating device 319 may be positioned on a contiguous surface ofthe substrate component 310, or may be partially embedded in a cavity inthe surface of the substrate component 310, or may be completelyembedded in a cavity in the surface of the substrate component 310 in amanner that an upper surface of the photovoltaic layer 315, the sensordevice 317 and the communicating device 319 substantially corresponds toan upper surface of the substrate component 310. In embodiments, a TFPVmaterial layer may be adhesively attached to, or formed on, thesubstrate component 310. In embodiments, a surface treatment may beapplied to portions of the surface of the substrate component 310 thatare not covered by the photovoltaic layer 315. The surface treatment,when applied, is intended to render an optical reflectance of theportions on which the surface treatment is applied to be substantiallyequal to an optical reflectance of the TFPV material layer in order toprovide a consistent undersurface for application of an energy/lightscattering layer.

As shown in FIG. 3C, an energy/light scattering layer 320 may be formedon/over the photovoltaic layer 315, the sensor device 317 and thecommunicating device 319 in a manner that first determined wavelengthsof the ambient light in the vicinity of the energy/light scatteringlayer 320 may pass through the energy/light scattering layer 320, in themanner described above with reference to the embodiments shown in FIGS.1 and 2, to activate either or both of the photovoltaic layer 315, andthe sensor device 317, while at least second determined wavelengths ofthe ambient light may be scattered back off the energy/light scatteringlayer 320 in the incident direction in the manner described above.

As shown in FIG. 3D, the laminated structure of the energy harvestingcomponent may be finished by covering, or even encapsulating, thelaminated structure in a substantially clear, protective overcoat orouter layer 325. This protective overcoat or outer layer 325 may be in aform, for example, of a clear coat finish.

FIG. 4 illustrates an exemplary embodiment of a detail of anenergy/light scattering layer 400 according to this disclosure. Thedisclosed schemes, processes, techniques or methods may produce anenergy/light scattering layer 400 created using substantiallytransparent multi-layer micron-sized particles 420. Those particles maybe in range of diameters of 5 microns or less embedded in asubstantially-transparent dielectric matrix 410. As an example, thesubstantially transparent multi-layer micron-sized particles 420 mayinclude titanium dioxide nanoparticles in a layered form. Titaniumdioxide is widely used based on its brightness and comparatively highrefractive index, strong ultraviolet (UV) light absorbing capabilities,and general resistance to discoloration under exposure to UV light.

In embodiments of the energy/light scattering layers, colorations of thelayered materials may be achieved through combinations of (1) materialcompositions of the particles, (2) material compositions of the binders,(3) nominal particle sizes, (4) nominal particle spacings, and (5)interplay between any or all of those material factors. That “interplay”is important. In other embodiments, the material interplay may becaptured in varying layers of a substantially transparent multi-layermicron-sized particle, thus requiring the only variables to becontrolled as particle size and particle physical composition. Capturingall of the physical parameters in the substantially transparentmulti-layer micron-sized particle substantially eliminates anyrequirement for constituent interplay between the particles and thebinder, essentially rendering the particles binder or matrix materialagnostic. In embodiments including the multi-layer particles, the binderor matrix material is provided simply to hold the particles where theyland. Spacing between the particles is rendered based on a substantiallyclear, neutral outer coating on the substantially transparentmulti-layer micron-sized particles, typically of a substantiallytransparent dielectric material having a comparatively low (less than 2)index of refraction. The employment of multi-layer particles providesincreased latitude in the use of randomized delivery methods, includingspray delivery of an aspirated composition of non-pigment particulatematerial suspended in a comparatively transparent or relatively clearbinder material.

In embodiments with particles comprised of layered constructions, a coresphere may have a diameter to accommodate an optical path length throughthe core of approximately one half wavelength of light for the color ofinterest and may be comprised of 15 or more individual material layerseach having a thickness to accommodate an optical path length throughthe layer of one quarter wavelength of light for the color of interest.For individualized colors from blue to red this layer-on-layerconstruction surrounding the core sphere may result in an overallparticle size of from about 1.9 microns up to 2.6 microns. This range ofoverall particle sizes for the multi-layered construction of thetransparent spheres is comparable to the typical ranges of diameters ofpaint pigment particles. Apparent colors, patterns or images of lightscattering layers may be produced by adjusting refractive indices of theparticles according to a size of the spherical core and the layers ofmaterial deposited on the spherical core of the particles. Such particlecompositions allow for additional degrees of freedom in adjusting thecolor, transmission and scattering, i.e., in “tuning” the energy/lightscattering effects produced by the composition of the energy/lightscattering layer. As mentioned above, an outer layer may be formed of aneutral, transparent, often dielectric material of a thickness selectedto provide a minimum required separation between the “colorant” layersof the substantially transparent multi-layer micron-sized particles toreduce instances of refractive interference thereby causing variation inthe color presentation provided by the light scattering layer.

Dielectric materials from which the core sphere and the dielectricmaterials may be selected may be chosen generally from a groupconsisting of titanium dioxide, silicon carbide, boron nitride, boronarsenite, aluminum nitride, aluminum phosphide, gallium nitride, galliumphosphide, cadmium sulfide, zinc oxide, zinc selenide, zinc sulfide,zinc telluride, cuprous chloride, tin dioxide, barium titanate,strontium titanate, lithium niobate, nickel oxide, and other similarmaterials.

Particle size is related to the wavelength of interest, in the mannerdescribed above, in order to determine the color of the substantiallytransparent multi-layer micron-sized particles. Spacing between theparticles is related to the size in order to reduce interference betweenthe refractions of separate particles. In embodiments, the binder indexof refraction may be the same as an outer layer of the particles inorder that the outer layer does not optically interact with the nextlayer inward. In such an instance, the outer layer may be thicker andparticle-to-particle optical interaction is minimized. Because wherethere is a difference in index of refraction (according to Snell's Law),a reflection occurs. When two reflections are spaced properly, theinteraction of multiple reflections is what provides the color.

The outer layer may be configured to ensure that the colorant producinglayers of the particles are kept separated. In an instance in which thecolorant producing layers touch, no interaction reflection is generated.A result of a configuration of a particle according to this scheme is aparticle that acts in a form of a Bragg Reflector. Multiple weakreflections of a same wavelength reinforce each other resulting in astrong reflection of a particular wavelength based on the particle size,which determines the particle spacing, and the index of refraction alsodetermines the speed of light which in turn describes the opticalwavelength. A number of particles per unit volume of solvent (matrixmaterial) essentially ensures that the particles always touch.

The outer layer will typically be thicker than the underlayers of whichthe substantially transparent multi-layer micron-sized particle iscomprised in order to attempt to ensure that safe separation ismaintained. If the outer layer is controlled to be composed of amaterial that is at a same index of refraction as the binder or matrixmaterial, the outer layer does not optically react in interaction withthe binder or matrix material. The outer layer will be transparent, andmaintain that transparency when immersed in thesubstantially-transparent binder or matrix material having a same indexof refraction as the outer layer of substantially transparentmulti-layer micron-sized particles. In this manner, the outermostlayers, in their composition and thickness, provide the essentialinterstitial spacing between the colorant components so as to assurecolor fidelity. The layers thus formed will yield only the color that is“built in” to the substantially transparent multi-layer micron-sizedparticles according to the structure of the color yielding/generatingunderlayers inward of the outermost layers in the manner describedbelow.

With enough layers, in a range of 10 to 15, to as many as 30, layers,color concentration would be high enough in each of the particles so asto not require external coloration reinforcement provided by adjacentmulti-layer particles. The outer layers are comparatively clear, as isthe binder or matrix solution, and preferably having a comparativelysame index of refraction as between the material forming the outerlayers and the material forming the binder solution. This is to ensurethat there is no interaction between the particles in the binder, and nointeraction between the particles, specifically the coloryielding/generating components of the particles over a longer distance.The outer layers may be comparatively, e.g., 10 times the thickness ofeach of the underlying dielectric layers.

The substantially transparent multi-layer micron-sized particles may beformed in a very tightly-controlled particle build process. A sphericalcore may be formed in a material or layer deposition process such as,for example, an atomic layer deposition (ALD) process, to achieve thesubstantially transparent multi-layer micron-sized particles accordingto the disclosed schemes. Particle deposition control systems exist thatcan be scaled to produce these substantially transparent multi-layermicron-sized particles. Quality control in the particle build processproduces the necessary level of color consistency. There are, however,deposition processes that can be controlled to the units of nanometersthicknesses.

Additionally, embodiments of the multi-layered particles may includemetallic layers sandwiched in between pairs of dielectric layers. Athickness of the metallic layers may be between 0.01 nm and 10 nm, aslong as the metallic layers remain substantially transparent. Thepresence of such metallic layers is intended to enhance reflectivityproperties with respect to the multi-layered structure of the coloryielding/generating layers of the substantially transparent multi-layermicron-sized particles. Indium titanium oxide (ITO) is an example of ametallic layer that is conductive, yet substantially transparent. Atypical touch screen on a cellular telephone, for example, includes anITO surface.

Any suitable acrylic, polyurethane, clearcoat, or like composed binderor matrix material having a low index of refraction may be adapted tosuspend the multi-layer micron-sized particles for application to abroad spectrum of substrate materials. These may include, but not belimited to, for example, synthetic or natural resins such as alkyds,acrylics, vinyl-acrylics, vinyl acetate/ethylene (VAE), polyurethanes,polyesters, melamine resins, epoxy, silanes or siloxanes or oils. It isenvisioned that, in the same manner that paint pigment particles aresuspended in solution, the substantially transparent multi-layermicron-sized particles according to this disclosure may be suspended insolution as well. Unlike paint pigment particles, however, the opticalresponse of particles according to the disclosed schemes will not “fade”over time because there is no pigment breakdown based on exposure to,for example, ultraviolet (UV) radiation. The disclosed particles mayalso be substantially insensitive to heat.

According to the above, application methodologies that are supportablewith particles according to the disclosed schemes include all of thoseapplication methodologies that are available for application of paints,inks and other coloration substances to substrates. These include thatthe particles suspended solutions can be brushed on, rolled on, sprayedon and the like. Separately, the particles may be pre-suspended in thesolutions for on-site apparatus mixing into the deliverable solutions atthe point of delivery to a substrate surface. The particles may bedelivered via conventional aspirated spray systems and/or via aerosolpropellants including being premixed with the propellants forconventional “spray can” delivery. Finally, the particles may be drydelivered to a binder-coated substrate. Conventional curing methods maybe employed to fix the binder-suspended particles on the varioussubstrates.

In the above-described manner, a finished and stabilized apparentcolored, multi-component colored, texturized or otherwiseimage-developed surface transparent light scattering layer is produced.Mass production of such layers could be according to known delivery,deposition and development methods for depositing the light scatteringlayer forming components on the base structures as layer receivingsubstrates, and automatically controlling the exposure, activationand/or stabilization of the surface components to achieve a particularcolored, multi-colored, texturized and/or image-wise patterned lightscattering layer surface.

Additives may be included in the binder or matrix materials in which thesubstantially transparent multi-layer micron-sized particles are, or areto be, suspended to enhance one or more of a capacity for adherence ofthe formed transmissive layer to a particular substrate, including anadhesive or the like, and a capacity for enhanced curing of the layer,including a photo initiator or the like.

FIG. 5 illustrates a schematic diagram of an exemplary communicationnetwork 500 within which a plurality of self-powered sensor andcommunication devices according to this disclosure may operate. One ormore self-powered sensor and communication devices 510-518 may beprovided in proximity to one another. When provided proximately to oneanother, the one or more self-powered sensor and communication devices510-518 may automatically communicatively coupled with one another inpairs or in multiples to create a form of an ad hoc mesh network inorder that communications from any one of the one or more self-poweredsensor and communication devices 510-518 may be transmitted via otherones of the one or more self-powered sensor and communication devices510-518 to a local sensor data collection point 520.

A local sensor data collection point 520 may be provided in a form of alocal transceiver that may communicate with one or more of theself-powered sensor and communication devices 510-518. The local sensordata collection point 520 may be configured to be limitedly visiblydetectable and to belie any conductivity with the one or moreself-powered sensor and communication devices 510-518 even if detected.The local sensor data collection point 520 may be configured tocommunicatively couple with either or both of a terrestrial data relaystation 530 and a communication satellite 540 in order to extend a rangeof data transmission from the one or more self-powered sensor andcommunication devices 510-518, for example, to a remote data collectionand analysis facility 550. The terrestrial data relay station 530 may bein a form of a radio transceiver, but also may be in a form of a Wi-Fi(or other communicating protocol) wireless access point with which thelocal sensor data collection point 520 may be configured to communicate.In this manner, for example, when the one or more self-powered sensorand communication devices 510-518 is configured as a tracking device onany one of, for example, a commercially shipped package, personalluggage in transit, a government-owned “trackable” asset, or the like,each of the one or more self-powered sensor and communication devices510-518, connecting independently with one another, may separatelyconnect with any wireless access portal, or may connect with a separatewireless local sensor data collection point 520 that may, in turn,connect with any wireless access portal. The system architecture,generally shown in FIG. 5, is intended to illustrate typicalcombinations of communications connections that may be exploited by theone or more self-powered sensor and communication devices 510-518according to this disclosure. In this regard, the depiction of thesystem architecture is not intended to be limiting in any way.

FIG. 6 illustrates a schematic diagram of an exemplary assembly lineusable for automated forming of the exemplary laminated energyharvesting, sensor, communication and other components on a substrate toform a self-powered sensor and communication device according to thisdisclosure. The exemplary system 600 may be used to prepare and buildthe laminated energy harvesting component structure in a manner similarto that described above with reference to FIGS. 3A-3D.

As shown in FIG. 6, the exemplary system 600 may include an assemblyline type transport component 640 which may be in a form of poweredroller elements 642, 644 about which a movable platform in a form of,for example, a conveyor belt 646 may be provided to move a substratepast multiple processing station 680, 682, 684, 686 in a direction A toaccomplish the layer forming and finishing elements of the laminatedenergy harvesting component build process. Operation of the transportcomponent may be controlled by a controller 660.

A photovoltaic array or TFPV and other element attachment station 610may be generally provided along the assembly line, or separately, as oneor more separate processing tasks, to provide for adhesive adherence of,for example, a TFPV material layer and other sensor and communicationelements on a surface of the substrate when the substrate is positionedat processing station 680. Operation of the TFPV and other elementattachment station 610 may be controlled by the controller 660.

A layer forming device 630 may be provided at, for example, processingstation 682 as the substrate is moved in direction A from processingstation 680. The layer forming device 630 may comprise a plurality ofspray nozzles or spray heads 636, 638, which may be usable to facilitatedeposition of a layer forming material over the previously placed TFPVmaterial layer on a surface of the substrate.

The layer forming device 630 may be connected to an air source 615 viapiping 617 and may separately be connected to a layer material reservoir620 via piping 622. The layer forming device 630 may be usable to obtaina flow of layer material from the layer material reservoir 620 andentrain that layer material in an airstream provided by the air source615 in a manner that causes aspirated layer material to be ejected fromthe spray nozzles or spray heads 636, 638 in a direction of thesubstrate when the substrate is positioned at processing station 682.

The layer material reservoir 620 may include separate chambers for asupply of substantially transparent micron-sized particles and for asupply of binder or matrix material. In embodiments, the particles andthe matrix material may come premixed, the particles and matrix materialmay be mixed in the layer material reservoir 620, or the particles andmatrix material may be separately fed to the layer forming device 630and mixed therein before being entrained in the airstream provided tothe layer forming device 630 by the air source 615. The layer formingdevice 630 may be a mounting structure or, in embodiments, the layerforming device 630 may be a movable structure mounted to the end of, forexample, an articulated arm 634 that is mounted to a base component 632.In embodiments, a particle and matrix material mixture may be providedin a material supply reservoir of a conventional spray gun with an airsource for delivery of the layer material in a delivery operationsimilar to a conventional spray painting of a surface. In embodiments,an entire surface of the substrate may be covered with the lightscattering layer material. In this manner, a consistency of colorationin the substrate finish may be obtained as between areas includingphotovoltaic arrays and areas of the substrate surface that do notinclude such underlying elements. Operation of the components of thelayer forming device 630 (including the articulated arm 634 and the basecomponent 632), the air source 615, and/or the layer material reservoir620, may be separately controlled by the controller 660.

The substrate may be translated then to a processing position 684opposite a layer curing station 650 that may employ known layer fixingmethods including using heat, pressure, photo-initiated chemicalreactions and the like to cure and/or finish the light scattering layerson the substrate surface. The substrate may then be translated to aprocessing station 686 opposite a surface finishing station 670 whichmay, for example, to deposit a clearcoat over an entire surface of thesubstrate, or undertake other finishing processing of the surface of thesubstrate.

The exemplary system 600 may operate under the control of a processor orcontroller 660. Layer and object forming information may be inputregarding at least one light scattering layer to be formed and fixed onan object or substrate by the exemplary system 600. The controller 660may be provided with object forming data that is devolved, or parsed,into component data to execute a controllable process in which one ormore light scattering layers are formed to produce a single color, amulti-color, texturized surface or an image-patterned presentation whenviewed from the viewing, observation or light incident side of afinished light scattering layer on the substrate.

The disclosed embodiments may include an exemplary method forintegrating a unique energy harvesting system, including an energy/lightscattering layer, sensor, communication and other components on asubstrate to form a self-powered sensor and communication device. FIG. 7illustrates a flowchart of such an exemplary method. As shown in FIG. 7,operation of the method commences at Step S700 and proceeds to StepS710.

In Step S710, one or more discrete substrate surfaces may be prepared toreceive a layer of TFPV material, and separately or coincidentally toreceive one or more of a sensor device, a wireless communicationcomponent, and supporting circuitry by which the individual componentsmay be electrically connected. Operation of the method proceeds to StepS720.

In Step S720, a layer of TFPV material may be applied to the preparedsubstrate surface according to an application method that may adhere thelayer of TFPV material to the substrate. Separately, the other elementsmay be adhered to the substrate. Compatible adhesive materials,including chemical, heat, or light activated adhesive materials, may beused to provide the adherence of the TFPV material layer and the otherelements to the substrate. It should be noted that portions of theparticular substrate, or other portions of the substrate, not covered bythe TFPV material or other elements may be separately or coincidentallyprepared with finishes that are comparable to the finish displayed bythe TFPV material layer in order that the substrate may provide aconsistent underlying appearance, particularly with regard to an opticalreflectance, for application of the energy transmissive layer materialsthereon. Operation of the method proceeds to Step S730.

In Step S730, the TFPV material layer and the other elements disposedon, or adhered to, the substrate may be electrically interconnected.Operation of the method proceeds to Step S740.

In Step S740, a liquefied mixture of components for forming an energytransmissive layer composed of substantially transparent particlessuspended in a substantially transparent liquefied matrix may bedeposited over the layer of TFPV material, or over an entire structureof the substrate. Such deposition may be according to any technique bywhich a liquefied matrix, which may appear in the form of the paint-likesubstance, may be applied to any substrate. In this regard, theliquefied mixture may be poured on, rolled on, brushed on, or sprayed onthe substrate surface. In this latter case, an airstream may be providedfrom an air source in which the liquefied mixture may be entrained asone of an aspirated and aerosol liquefied mixture. Operation of themethod proceeds to Step S750.

As indicated above, in embodiments, the liquefied mixture may includeformed multi-layered substantially transparent particles suspended in asubstantially transparent liquefied matrix material to form theliquefied mixture. The substantially transparent liquefied matrixmaterial may be selected to have an index of refraction similar to thesubstantially clear outer layers or shells of the substantiallytransparent particles in order to substantially reduce any potential forrefractive interference between adjacent particles when deposited on thesubstrate surface. The substantially transparent liquefied matrixmaterial may include components to aid in adherence of the finishedenergy transmissive layers on the portions of the substrate surface onwhich those layers are ultimately formed. The substantially transparentliquefied matrix material may include components to aid in fixing of thesubstantially transparent particles in the layer, includingheat-activated and/or light-activated hardeners. The sizing of theparticles to be less than 5 microns expands the latitude by which thesubstantially transparent particles suspended in the matrix material maybe delivered to the substrate surface by rendering those particlescompatible with the spray techniques discussed above. As such, in adelivery process that mirrors conventional spray painting, the aspiratedliquefied mixture may be deposited on the prepared surface to form theenergy transmissive layer that passes certain wavelengths ofenergy/light through the layer based and scatters other selectablewavelengths of energy/light to render a perceptibly single color,multi-color, patterned, texturized or image-wise presentation ofscattered light from the light incident surface based on one or moredelivery passes for depositing the energy transmissive layer materialsaccording to the above-described schemes.

In Step S750, the deposited liquefied mixture may be developed, cured,or otherwise fixed over the TFPV material layer, the other elements andon any other portions of the substrate onto which the liquefied mixtureis deposited for coloration of those portions of the substrate to form afixed energy transmissive layer thereon. Operation of the methodproceeds to Step S760.

In Step S760, a protective coating may be applied over the energytransmissive layer. The protective coating may take a form of, forexample, a commercial clearcoat finishing composition. Operation of themethod proceeds to Step S770.

In Step S770, the applied protective coating may be cured or otherwisefixed over the energy transmissive layer formed on the surface of thesubstrate. Operation of the method proceeds to Step S780.

In Step S780, finished processing and operational testing of athus-configured self-powered sensor and communication device may becompleted according to known methods. Operation of the method proceedsto Step S790, where operation of the method ceases.

The above-described exemplary particle and material formulations,layered component build processes, and systems and methods for applyinglaminated energy harvesting and other components to portions of asubstrate reference certain conventional components, energy harvestingelements, sensor elements, communication components, materials, andreal-world use cases to provide a brief, general description of suitableoperating, product processing, energy/light scattering (transmissive)layer forming and substrate modification and integration environments inwhich the subject matter of this disclosure may be implemented forfamiliarity and ease of understanding. Although not required,embodiments of the disclosure may be provided, at least in part, in aform of hardware control circuits, firmware, or softwarecomputer-executable instructions to control or carry out the laminatedstructure development functions described above. These may includeindividual program modules executed by processors.

Those skilled in the optics, electrical generation and sensor andcommunication arts will appreciate that other embodiments of thedisclosed subject matter may be practiced in many disparate filmforming, layer forming, laminate layer forming and component productionsystems, techniques, processes and/or devices, including variousmachining, molding, additive and subtractive layer forming andmanufacturing methods, of many different configurations.

Embodiments within the scope of this disclosure may include processorcomponents that may implement certain of the steps described above viacomputer-readable media having stored computer-executable instructionsor data structures recorded thereon that can be accessed, read andexecuted by one or more processors for controlling the disclosedenergy/light scattering layer forming and integration schemes. Suchcomputer-readable media can be any available media that can be accessedby a processor, general purpose or special purpose computer. By way ofexample, and not limitation, such computer-readable media can compriseRAM, ROM, EEPROM, CD-ROM, flash drives, data memory cards or otheranalog or digital data storage device that can be used to carry or storedesired program elements or steps in the form of accessiblecomputer-executable instructions or data structures for carrying intoeffect, for example, computer-aided design (CAD) or computer-aidedmanufacturing (CAM) of particular objects, object structures, layers,and/or layer components.

Computer-executable instructions include, for example, non-transitoryinstructions and data that can be executed and accessed respectively tocause a processor to perform certain of the above-specified functions,individually or in various combinations. Computer-executableinstructions may also include program modules that are remotely storedfor access and execution by a processor.

The exemplary depicted sequence of method steps represent one example ofa corresponding sequence of acts for implementing the functionsdescribed in the steps of the above-outlined exemplary method. Theexemplary depicted steps may be executed in any reasonable order tocarry into effect the objectives of the disclosed embodiments. Noparticular order to the disclosed steps of the methods is necessarilyimplied by the depiction in FIG. 7, except where a particular methodstep is a necessary precondition to execution of any other method step.

Although the above description may contain specific details, they shouldnot be construed as limiting the claims in any way. Other configurationsof the described embodiments of the disclosed systems and methods arepart of the scope of this disclosure.

It will be appreciated that various of the above-disclosed and otherfeatures and functions, or alternatives thereof, may be desirablycombined into many other different systems or applications. Also,various alternatives, modifications, variations or improvements thereinmay be subsequently made by those skilled in the art which are alsointended to be encompassed by the following claims.

We claim:
 1. A method for integrating an energy harvesting system in aself-powered sensor device, comprising: arranging an energy harvestingelement in a body structure; arranging a sensor device in the bodystructure, the sensor device being powered by electrical energygenerated by the energy harvesting element and configured to generate anoutput signal according to a sensed parameter measured by the sensordevice; electrically connecting the sensor device and the energyharvesting element such that the sensor device and the energy harvestingelement are in electrical communication; and arranging an energytransmissive layer over the energy harvesting element on a surface ofthe body structure, the energy transmissive layer having a body-facingside facing the surface of the body structure, and an energy-incidentside opposite the body-facing side, the energy-incident side presentinga consistent opaque appearance when viewed from substantially anyaspect, and the energy transmissive layer passing 50% or more of lightenergy impinging on the energy transmissive layer through the energytransmissive layer to activate the energy harvesting element.
 2. Themethod of claim 1, further comprising: providing an electrical energystorage device in the body structure; and electrically connecting theelectrical energy storage device to the energy harvesting element, theelectrical energy storage device being configured to store electricalenergy generated by the energy harvesting element.
 3. The method ofclaim 1, further comprising: providing a first wireless communicatingdevice in the body structure; electrically connecting the first wirelesscommunicating device to the energy harvesting element; communicativelyconnecting the first wireless communicating device to the sensor device,the first wireless communicating device being configured to establishcommunication with at least one of (1) a second wireless communicatingdevice of at least one second self-powered sensor device, and (2) areceiver unit of the second self-powered sensor device located remotelyfrom the self-powered sensor device, the first wireless communicatingdevice being configured to transmit first data communications based onthe output signal of the sensor device.
 4. The method of claim 3,further comprising: providing a geolocation device in the bodystructure, the geolocation device being configured to determine alocation of the self-powered sensor device and to generate a locationoutput signal; electrically connecting the geolocation device to theenergy harvesting element; and communicatively connecting thegeolocation device to the first wireless communicating device, the firstwireless communicating device being configured to transmit second datacommunications based on the location output signal.
 5. The method ofclaim 3, further comprising: providing a processor in the bodystructure; electrically connecting the processor to the energyharvesting element; and communicatively connecting the processor to thesensor device and the first wireless communicating device, the processorbeing programmed to control operation of the sensor device and the firstwireless communicating device; and convert the output signal of thesensor device to the first data communications for transmission by thefirst wireless communicating device.
 6. The method of claim 1, furthercomprising forming the energy transmissive layer of a materialcomposition comprising a plurality of substantially-transparentparticles and a substantially-transparent matrix material that fixes theplurality of substantially-transparent particles in a layer arrangementto form the energy transmissive layer.
 7. The method of claim 6, furthercomprising fixing the plurality of substantially-transparent particlesin the matrix material in a manner that causes the energy-incident sideto reflect substantially all of one or more selectable wavelengths ofthe impinging light energy in all directions on the energy-incident sideto present the consistent opaque appearance.
 8. The method of claim 6,further comprising forming each of the plurality ofsubstantially-transparent particles of: a spherical core formed of afirst transparent dielectric material, the spherical core having a valueof a physical diameter equal to a half wavelength of a first selectedcolor of light component to be reflected by thesubstantially-transparent particle modified by a first refractive indexof the first transparent dielectric material; a plurality of materiallayers disposed radially outwardly from the spherical core, each of theplurality of material layers being formed of at least a secondtransparent dielectric material, and having a value of a physicalthickness equal to a quarter wavelength of at least a second selectedcolor of light component to be reflected by thesubstantially-transparent particle modified by a second refractive indexof the at least the second transparent dielectric material; and an outercoating comprised of another transparent dielectric material having aselected index of refraction of 2 or less, the outer coating having athickness that substantially eliminates reflective interference betweencolors reflected by adjacent particles when in contact with one another.9. The method of claim 8, further comprising adjusting an index ofrefraction of the substantially transparent liquid matrix material to bea same index of refraction as the outer coating.
 10. The method of claim6, the energy harvesting element comprising a photovoltaic element. 11.The method of claim 10, the photovoltaic element being a photovoltaicfilm (PVF) material.
 12. The method of claim 11, further comprisingapplying the PVF material to one or more discrete portions of thesurface of the body structure.
 13. The method of claim 12, furthercomprising applying a layer of adhesive to the one or more discreteportions of the surface of the body structure before applying the PVFmaterial to the one or more discrete portions, the layer of adhesiveaffixing the PVF material to the surface of the body structure in theone or more discrete portions.
 14. The method of claim 6, the arrangingthe energy transmissive layer over the energy harvesting element on thesurface of the body structure comprising: delivering the materialcomposition in a liquid form; and applying one of heat or light energyto fix the material composition to form the energy transmissive layer onthe body structure.
 15. The method of claim 14, each of thesubstantially-transparent particles having a diameter in a range of 5microns or less.
 16. The method of claim 15, each of thesubstantially-transparent particles having a diameter in a range of 1.0to 3.0 microns.
 17. The method of claim 16, the delivering the materialcomposition in a liquid form comprising: entraining the materialcomposition in an air stream; and spraying the entrained materialcomposition on the surface of the body structure.
 18. The method ofclaim 14, further comprising separately entraining the plurality ofsubstantially-transparent particles and the substantially-transparentmatrix material in the air stream to form the material compositionsprayed on the surface of the body structure.
 19. The method of claim 1,further comprising arranging a substantially transparent protectivecoating over the energy transmissive layer.
 20. The method of claim 1,the energy transmissive layer being arranged to pass 80% or more oflight energy impinging on the energy transmissive layer through theenergy transmissive layer to activate the energy harvesting element.